Additive manufacturing of three-dimensional articles

ABSTRACT

The present invention relates to a method for forming a three-dimensional article through successively depositing individual layers of powder material that are fused together so as to form the article, the method comprising the step of heating a first portion of a support surface while depositing a layer of powder material on a second portion of the support surface.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to and the benefit of U.S.Non-Provisional application Ser. No. 14/547,584, filed Nov. 19, 2014,which application further claims priority to and the benefit of U.S.Provisional Patent Application Ser. No. 61/917,759, filed Dec. 18, 2013,the contents of both of which as are hereby incorporated by reference intheir entirety.

BACKGROUND Related Field

The present invention relates to a method for additive manufacturing ofa three dimensional article by successively fusing individual layers ofpowder material.

Description of Related Art

Freeform fabrication or additive manufacturing is a method for formingthree-dimensional articles through successive fusion of chosen parts ofpowder layers applied to a worktable. A method and apparatus accordingto this technique is disclosed in US 2009/0152771.

An additive manufacturing apparatus may comprise a work table on whichthe three-dimensional article is to be formed, a powder dispenser orpowder distributor, arranged to lay down a thin layer of powder on thework table for the formation of a powder bed, a high energy beam fordelivering energy to the powder whereby fusion of the powder takesplace, elements for control of the energy given off by the energy beamover the powder bed for the formation of a cross section of thethree-dimensional article through fusion of parts of the powder bed, anda controlling computer, in which information is stored concerningconsecutive cross sections of the three-dimensional article. Athree-dimensional article is formed through consecutive fusions ofconsecutively formed cross sections of powder layers, successively laiddown by the powder dispenser.

In additive manufacturing a short manufacturing time and high quality ofthe finalized product is of outmost importance. However, decreasing themanufacturing time may reduce the material properties of the3-dimensional article which is produced, which is a problem.

BRIEF SUMMARY

An object of the invention is to provide a method which reduces themanufacturing time and at the same time improves or at least maintainsthe material characteristics of the manufactured three-dimensionalarticle.

The above mentioned object is achieved by the features in the methodaccording to claim 1.

In a first aspect of the invention it is provided a method for forming athree-dimensional article through successively depositing individuallayers of powder material that are fused together so as to form thearticle. The method comprising the step of: depositing a new layer ofpowder material with a powder distributor on top of a support surface,heating the new layer of powder material and/or the support surfacewhile depositing the new layer of powder material.

If heating is applied during the powder application process therequirement for heating in between the finalized powder application andthe fusion process may be decreased or eliminated.

If a local heating of the previous layer or support layer just in frontof the powder which is to be distributed is performed so that theprevious layer will achieve a predetermined minimum temperature, thepowder which is then applied on the previous layer or support layer mayself-sinter, i.e., if the heat from the previous layer or support layeris sufficiently high, the new powder layer which is distributed over theprevious layer or support layer may slightly bond to the previous layeror support layer and/or the powder particles in the new powder layer maybond to each other. This may decrease or completely eliminate therequirement of a later preheating when the new powder layer iscompleted. The self-sintering may also enable a lower fusiontemperature. This is because the local heating just in front of thepowder to be distributed has been elevated to a temperature which willenable the new powder layer to self-sinter. The power input to thislocal area, which may be a line with a predetermined thickness at apredetermined distance from the powder to be distributed, may be loweror much lower compared to heating a full powder layer to a sinteringtemperature. Another advantage is that the fusion process may take placeas soon as the powder distribution is finalized, which is much fastercompared to first distributing a full new powder layer and thenperforming the preheating of the new powder layer.

In still another example embodiment of the present invention the newlayer of powder material is heated to maintain a predeterminedtemperature interval before fusing the layer of powder material.

An advantage of this embodiment is that the temperature of the newlyapplied powder layer which is possibly self-sintered may be kept to adesired temperature interval by applying a predetermined power input tothe new powder layer.

In yet another example embodiment an energy beam for fusing the powdermaterial for forming the three-dimensional article and the energy beamfor heating the support layer and/or the new layer of powder material isthe same energy beam.

An advantage of this embodiment is that the heating of the powder layerand the later on fusion process of the same powder layer may beperformed by one and the same energy source with decreased manufacturingtime compared to the prior art methods.

In still another example embodiment of the present invention the energybeam for preheating and the energy beam for fusion is a plurality ofbeams.

The advantage of this is that the heating process may be performed witha first number of energy beams and the later on fusion process may beperformed with a second number of energy beams. The first number may besmaller, equal or larger than the second number.

In still another example embodiment of the present invention at least afirst energy beam is heating the support surface while at least a secondenergy beam is heating the new layer of powder material.

An advantage of this embodiment is that simultaneous and independentheating of the support surface and the new layer of powder material maytake place.

In still another example embodiment the energy beam is switched off whenmoving the energy beam from heating the support surface to heating thenew layer of powder material or vice versa.

If a single energy beam is used for heating the support surface orprevious powder layer and the new layer of powder material the energybeam maybe switched off while passing over the powder distributor foreliminating an unnecessary heating of the powder distributor which maycause undesirable attachment of powder particles onto it.

In still another example embodiment of the present invention the firstenergy beam is of a first type and the second energy beam is of a secondtype.

According to another aspect of this invention, a program element isprovided. The program element configured and arranged when executed on acomputer to implement a method for forming a three-dimensional articlethrough successively depositing individual layers of powder materialthat are fused together so as to form the article. The method comprisesthe steps of depositing a new layer of powder material with a powderdistributor on top of a support surface; and heating said new layer ofpowder material and/or said support surface while depositing said newlayer of powder material.

According to another aspect of this invention, a non-transitory computerprogram product comprising at least one non-transitory computer-readablestorage medium having computer-readable program code portions embodiedtherein. According to various embodiments, the computer-readable programcode portions comprise: an executable portion configured for depositinga new layer of powder material with a powder distributor on top of asupport surface; and an executable portion configured for heating saidnew layer of powder material and/or said support surface whiledepositing said new layer of powder material.

An advantage of certain of the above-described embodiments is thatheating of non-sintered powder may be more suitable with a first typewhich may be a laser beam and the heating of the previous layer may bemore suitable with a second type which may be an electron beam.

Further advantages of the present invention may be apparent from thefigures and the various embodiments disclosed herein below.

All examples and exemplary embodiments described herein are non-limitingin nature and thus should not be construed as limiting the scope of theinvention described herein. Still further, the advantages describedherein, even where identified with respect to a particular exemplaryembodiment, should not be necessarily construed in such a limitingfashion.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S)

Having thus described the invention in general terms, reference will nowbe made to the accompanying drawings, which are not necessarily drawn toscale, and wherein:

FIG. 1A depicts a perspective view of an example embodiment of a buildtank, in which a first example embodiment of an inventive heatingconcept may be implemented while building a three-dimensional article;

FIG. 1B depicts a perspective view of an example embodiment of a buildtank, in which a second example embodiment of an inventive heatingconcept may be implemented while building a three-dimensional article;

FIG. 1C depicts a perspective view of an example embodiment of a buildtank, in which a third example embodiment of an inventive heatingconcept may be implemented while building a three-dimensional article;

FIG. 2 depicts, in a schematic view, an apparatus for producing a threedimensional product according to prior art;

FIG. 3 is a block diagram of an exemplary system 1020 according tovarious embodiments;

FIG. 4A is a schematic block diagram of a server 1200 according tovarious embodiments; and

FIG. 4B is a schematic block diagram of an exemplary mobile device 1300according to various embodiments.

DETAILED DESCRIPTION OF VARIOUS EMBODIMENTS

Various embodiments of the present invention will now be described morefully hereinafter with reference to the accompanying drawings, in whichsome, but not all embodiments of the invention are shown. Indeed,embodiments of the invention may be embodied in many different forms andshould not be construed as limited to the embodiments set forth herein.Rather, these embodiments are provided so that this disclosure willsatisfy applicable legal requirements. Unless otherwise defined, alltechnical and scientific terms used herein have the same meaning ascommonly known and understood by one of ordinary skill in the art towhich the invention relates. The term “or” is used herein in both thealternative and conjunctive sense, unless otherwise indicated. Likenumbers refer to like elements throughout.

Still further, to facilitate the understanding of this invention, anumber of terms are defined below. Terms defined herein have meanings ascommonly understood by a person of ordinary skill in the areas relevantto the present invention. Terms such as “a”, “an” and “the” are notintended to refer to only a singular entity, but include the generalclass of which a specific example may be used for illustration. Theterminology herein is used to describe specific embodiments of theinvention, but their usage does not delimit the invention, except asoutlined in the claims.

The term “three-dimensional structures” and the like as used hereinrefer generally to intended or actually fabricated three-dimensionalconfigurations (e.g., of structural material or materials) that areintended to be used for a particular purpose. Such structures, etc. may,for example, be designed with the aid of a three-dimensional CAD system.

The term “electron beam” as used herein in various embodiments refers toany charged particle beam. The sources of charged particle beam caninclude an electron gun, a linear accelerator and so on.

FIG. 2 depicts an embodiment of a freeform fabrication or additivemanufacturing apparatus 21 in which the inventive method according tothe present invention may be implemented.

The apparatus 21 comprising an electron beam gun 6; deflection coils 7;two powder hoppers 4, 14; a build platform 2; a build tank 10; a powderdistributor 28; a powder bed 5; and a vacuum chamber 20.

The vacuum chamber 20 is capable of maintaining a vacuum environment bymeans of or via a vacuum system, which system may comprise aturbomolecular pump, a scroll pump, an ion pump and one or more valveswhich are well known to a skilled person in the art and therefore needno further explanation in this context. The vacuum system is controlledby a control unit 8.

The electron beam gun 6 is generating an electron beam which is used formelting or fusing together powder material provided on the buildplatform 2. At least a portion of the electron beam gun 6 may beprovided in the vacuum chamber 20. The control unit 8 may be used forcontrolling and managing the electron beam emitted from the electronbeam gun 6. At least one focusing coil (not shown), at least onedeflection coil 7, an optional coil for astigmatic correction (notshown) and an electron beam power supply (not shown) may be electricallyconnected to the control unit 8. In an example embodiment of theinvention the electron beam gun 6 generates a focusable electron beamwith an accelerating voltage of about 15-60 kV and with a beam power inthe range of 3-10 Kw. The pressure in the vacuum chamber may be 10⁻³mbar or lower when building the three-dimensional article by fusing thepowder layer by layer with the energy beam.

The powder hoppers 4, 14 comprise the powder material to be provided onthe build platform 2 in the build tank 10. The powder material may forinstance be pure metals or metal alloys such as titanium, titaniumalloys, aluminum, aluminum alloys, stainless steel, Co-Cr alloys, nickelbased superalloys, etc.

The powder distributor 28 is arranged to lay down a thin layer of thepowder material on the build platform 2. During a work cycle the buildplatform 2 will be lowered successively in relation to a fixed point inthe vacuum chamber. In order to make this movement possible, the buildplatform 2 is in one embodiment of the invention arranged movably invertical direction, i.e., in the direction indicated by arrow P. Thismeans that the build platform 2 starts in an initial position, in whicha first powder material layer of necessary thickness has been laid down.Means for lowering the build platform 2 may for instance be through aservo engine equipped with a gear, adjusting screws, etc. The servoengine may be connected to the control unit 8.

An electron beam may be directed over the build platform 2 causing thefirst powder layer to fuse in selected locations to form a first crosssection of the three-dimensional article 3. The beam is directed overthe build platform 2 from instructions given by the control unit 8. Inthe control unit 8 instructions for how to control the electron beam foreach layer of the three-dimensional article is stored. The first layerof the three dimensional article 3 may be built on the build platform 2,which may be removable, in the powder bed 5 or on an optional startplate 16. The start plate 16 may be arranged directly on the buildplatform 2 or on top of a powder bed 5 which is provided on the buildplatform 2.

After a first layer is finished, i.e., the fusion of powder material formaking a first layer of the three-dimensional article, a second powderlayer is provided on the build platform 2. The second powder layer is incertain embodiments preferably distributed according to the same manneras the previous layer. However, there might be alternative methods inthe same additive manufacturing machine for distributing powder onto thework table. For instance, a first layer may be provided via or by meansof a first powder distributor 28, a second layer may be provided byanother powder distributor. The design of the powder distributor isautomatically changed according to instructions from the control unit 8.A powder distributor 28 in the form of a single rake system, i.e., whereone rake is catching powder fallen down from both a left powder hopper 4and a right powder hopper 14, the rake as such can change design.

After having distributed the second powder layer on the build platform,the energy beam is directed over the work table causing the secondpowder layer to fuse in selected locations to form a second crosssection of the three-dimensional article. Fused portions in the secondlayer may be bonded to fused portions of the first layer. The fusedportions in the first and second layer may be melted together by meltingnot only the powder in the uppermost layer but also remelting at least afraction of a thickness of a layer directly below the uppermost layer.

In the case where an electron beam is used, it is necessary to considerthe charge distribution that is created in the powder as the electronshit the powder bed 5. The charge distribution density depends on thefollowing parameters: beam current, electron velocity (which is given bythe accelerating voltage), beam scanning velocity, powder material andelectrical conductivity of the powder, i.e., mainly the electricalconductivity between the powder grains. The latter is in turn a functionof several parameters, such as temperature, degree of sintering andpowder grain size/size distribution.

Thus, for a given powder, i.e., a powder of a certain material with acertain grain size distribution, and a given accelerating voltage, it ispossible, by varying the beam current (and thus the beam power) and thebeam scanning velocity, to affect the charge distribution.

By varying these parameters in a controlled way, the electricalconductivity of the powder can gradually be increased by increasing thetemperature of the powder. A powder that has a high temperature obtainsa considerably higher conductivity which results in a lower density ofthe charge distribution since the charges quickly can diffuse over alarge region. This effect is enhanced if the powder is allowed to beslightly sintered during a pre-heating process. When the conductivityhas become sufficiently high, the powder can be fused together, i.e.,melted or fully sintered, with predetermined values of the beam currentand beam scanning velocity.

In another embodiment a laser beam may be used for melting or fusing thepowder material. In such case tiltable mirrors may be used in the beampath in order to deflect the laser beam to a predetermined position.

FIG. 1A depicts a perspective view of an example embodiment of a buildtank 10 in which a first example embodiment of an inventive heatingconcept may be implemented while building a three-dimensional article.The build tank comprises a build platform 2, which is movable up anddown according to the arrow P, and a powder distributor 28. The buildplatform 2 inside the build tank 10 is depicted to have a rectangularshape, obviously the build tank may have any desirable shape. In FIG. 1Athe powder distributor 28 is applying a new powder layer on a previouslypartly fused powder layer.

In FIG. 1A there are essentially three different regions when applying anew powder layer. A first region, which is denoted by A, is the topsurface of the new powder layer. A second region, which is denoted by B,is the top surface of the previous partially fused powder layer. A thirdregion, which is denoted by 108, is the powder to be distributed on topof the second region B.

The new powder layer in the first region A is heated according to theinvention by an energy beam while the powder layer is applied on top ofthe previous partially fused powder layer. The application of a fullpowder layer takes time. During the time the temperature of the powderlayer may decrease under a predetermined minimum temperature. This mayrequire a preheating of the powder layer before the fusion takes place.Instead of waiting until the full powder layer has been applied on topof the previous partially fused powder layer, the heating of the newlyapplied powder layer may be done during the powder distribution. In FIG.1A an energy beam is heating the new powder layer in region A, this isdenoted by a line 104. When heating of the powder layer is performedduring the application of a powder layer, any additional heatingrequired when the powder layer has been completed may be minimized orcompletely eliminated for achieving a predetermined temperature intervalof the new layer to be fused. The heating may be performed by the sameenergy source as is later used for fusing the powder layer in selectedlocations. In another embodiment a separate heating source is used forheating and another source is used for fusing the powder material. Theheating source may be a laser source, electron beam source, IR source ora resistive heating source. The source for fusing the powder materialmay be a laser source and/or an electron beam source.

In FIG. 1A the heating, denoted by line 104, of the newly applied powderlayer is set to be at a predetermined distance d from the powderdistributor 28. The distance d is a safety distance of a heating spotfrom the powder distributor. If the heating of the powder material istoo close to the powder distributor the powder distributor itself may beheated to an undesirable high temperature which may cause the powdermaterial to stick at the powder distributor. In FIG. 1A the heating isdenoted to be a straight line 104. However, any means of heating thefirst region A may be used, such as meander formed heating lines orrandomly distributed scan lines of a predetermined length. In an exampleembodiment a temperature measurement of the newly applied powder layerin the first region A may be performed and the heating may beprioritized at the regions where the temperature is lowest. Thetemperature measurement may be done by a temperature sensitive camera,e.g., a IR camera. The IR picture from the IR camera is transformed intoa 2-dimensional temperature map of the first region A. The heatingsource may be instructed by a control unit to apply a predeterminedheating powder at predetermined locations in order to achieve ashomogenous surface temperature as possible of the new powder layer inthe first region A. In an example embodiment the temperature to whichthe new powder layer is elevated to is sufficient for the new powderlayer to sinter, i.e., a sufficient temperature for bonding powderparticles together in the new powder layer and/or bonding the new powderlayer to the underlying layer, but not as high as to create a fusion ofthe powder particles.

When maintaining a predetermined temperature interval of the new powderlayer the fusion process may be more predictable. If the temperature inwhich the new powder layer is maintained at is set to be in atemperature interval just below the melting point, the energy which isrequired for melting the new layer and also remelting a sufficientportion of the previous layer is more predictable. For this reason amore homogenous and predictable microstructure of the solidifiedportions of the three-dimensional article can be achieved.

The heating position of the new powder layer may be synchronized withthe movement of the powder distributor 28 in order to keep track of theposition of the powder distributor 28 and also keep track of theconstantly increased area of the first region A as the powderapplication is going on. The powder distributor 28 is moving in adirection of the arrow 50 in FIG. 1A-1C.

In another embodiment a plurality of energy beams may be used forheating the first region A of the new powder layer. The plurality ofbeams may be of the same type, i.e., a plurality of laser beams or aplurality of electron beams. In another embodiment the plurality ofenergy beams may be of different types, i.e., one or several laser beamsand one or several electron beams.

FIG. 1B depicts a perspective view of an example embodiment of a buildtank 10 in which a second example embodiment of an inventive heatingconcept may be implemented while building a three-dimensional article.

The build tank comprises the same features as the build tank depicted inFIG. 1A. The heating concept is somewhat different to what is disclosedin connection with FIG. 1A. Here in FIG. 1B not only the newly appliedpowder layer in the first region A is heated by at least one energy beamas depicted in FIG. 1A by line 104, but also the second region B isheated by at least one energy beam denoted by 110.

The second region B may be heated to a predetermined temperatureinterval prior to applying the new powder layer and thereby enabling thenew powder layer to self-sinter, i.e., the temperature interval may besufficiently high for the powder particles in the new powder layer to beslightly bonded to the underlying layer and/or slightly bonded to eachother, but sufficiently low for prohibiting the powder particles to befused/melted.

The heating of the second region B with at least one energy beam may beperformed at a security distance denoted by “e” in FIG. 1B from thethird region 108 comprising the powder to be distributed. The securitydistance e may be set for prohibiting the powder in region 108 to bedistributed to self-sinter before it is applied on top of the previouspartially fused powder layer.

In an example embodiment the first region A may be heated with a firstenergy beam source and the second region B with a second energy beamsource. The first and second energy beam sources may be of the same typeor different type, i.e., the first energy beam source may be a laserbeam source and the second energy beam source may be an electron beamsource. In another embodiment the first and second energy beam sourcesmay be of the same type, i.e., laser beam source or electron beamsource.

In still another example embodiment the first region may be heated witha plurality of energy beam sources and the second region may be heatedwith a plurality of energy beam sources.

In still another example embodiment one and the same energy beam sourcemay be used for heating the first and the second region, i.e., a singleenergy beam source is used for heating on both sides of the powderdistributor 28. In this embodiment it may be preferable to switch offthe energy beam source while passing the powder distributor forprohibiting unnecessary temperature increase of the powder distributorand the not yet distributed powder in front of the powder distributor28. In another embodiment, the energy beam may be greatly defocusedwhile passing the powder distributor for eliminating or at least reducethe impact of the energy beam onto the powder distributor and the nonapplied powder. When the energy beam is in a desired position forheating, the energy beam may be focused to a predetermined level forheating the first or second region, A and B respectively, to a desiredlevel. When using a single energy beam for heating the first and secondregion the position of the energy beam may be synchronized with theposition of the powder distributor 28 for keeping track of the positionof the powder distributor and for allowing the energy beam to know thesize of the first and second region which is constantly changing whilethe powder distributor is moving forward.

As in FIG. 1A, in FIG. 1B the heating is denoted to be straight lines104, 110. However, any means of heating the regions A,B may be used,such as meander formed heating lines or randomly distributed scan linesof a predetermined length.

FIG. 1C depicts a perspective view of an example embodiment of a buildtank 10 in which a third example embodiment of an inventive heatingconcept may be implemented while building a three-dimensional article.

In the third example embodiment of the heating concept according to thepresent invention the heating is only performed in the second region Bwhere the powder has not yet been applied. As in FIG. 1B there is asafety distance e between the powder to be distributed and the line ofheating 110 the second region. The safety distance is used for the samereason as already has been explained in relation to FIG. 1B. The heatingof the second region may be to a sufficiently high predeterminedtemperature interval allowing the new powder layer to self-sinter whenit is applied on top of the heated surface. In another embodiment thepowder is not allowed to self-sinter, i.e., the temperature interval ischosen to be lower than the self-sintering temperature for the type ofpowder material to be distributed. The temperature is not allowed to beso high so that the powder particles will be fused. The fusion of theparticles will take place in a following step when the new powder layeris completed over the previous partially fused layer and its temperatureis falling within a predetermined temperature interval.

In an example embodiment the energy beam for fusing the powder layer maybe the same energy beam source which is used for heating at least one ofthe first or second regions.

As in FIG. 1B, in FIG. 1C the heating is denoted to be a straight line110. However, any means of heating the region B may be used, such asmeander formed heating lines or randomly distributed scan lines of apredetermined length.

In another aspect of the invention it is provided a program elementconfigured and arranged when executed on a computer to implement amethod for forming a three-dimensional article through successivelydepositing individual layers of powder material that are fused togetherso as to form the article. The program may be installed in a computerreadable storage medium. The computer readable storage medium may be thecontrol unit 8 described elsewhere herein or another separate anddistinct control unit, or another comparable device, as desirable andwell-known. The computer readable storage medium and the programelement, which may comprise computer-readable program code portionsembodied therein, may further be contained within a non-transitorycomputer program product. Further details in this regard are providedelsewhere herein.

As mentioned, various embodiments of the present invention may beimplemented in various ways, including as non-transitory computerprogram products. A computer program product may include anon-transitory computer-readable storage medium storing applications,programs, program modules, scripts, source code, program code, objectcode, byte code, compiled code, interpreted code, machine code,executable instructions, and/or the like (also referred to herein asexecutable instructions, instructions for execution, program code,and/or similar terms used herein interchangeably). Such non-transitorycomputer-readable storage media include all computer-readable media(including volatile and non-volatile media).

In one embodiment, a non-volatile computer-readable storage medium mayinclude a floppy disk, flexible disk, hard disk, solid-state storage(SSS) (e.g., a solid state drive (SSD), solid state card (SSC), solidstate module (SSM)), enterprise flash drive, magnetic tape, or any othernon-transitory magnetic medium, and/or the like. A non-volatilecomputer-readable storage medium may also include a punch card, papertape, optical mark sheet (or any other physical medium with patterns ofholes or other optically recognizable indicia), compact disc read onlymemory (CD-ROM), compact disc compact disc-rewritable (CD-RW), digitalversatile disc (DVD), Blu-ray disc (BD), any other non-transitoryoptical medium, and/or the like. Such a non-volatile computer-readablestorage medium may also include read-only memory (ROM), programmableread-only memory (PROM), erasable programmable read-only memory (EPROM),electrically erasable programmable read-only memory (EEPROM), flashmemory (e.g., Serial, NAND, NOR, and/or the like), multimedia memorycards (MMC), secure digital (SD) memory cards, SmartMedia cards,CompactFlash (CF) cards, Memory Sticks, and/or the like. Further, anon-volatile computer-readable storage medium may also includeconductive-bridging random access memory (CBRAM), phase-change randomaccess memory (PRAM), ferroelectric random-access memory (FeRAM),non-volatile random-access memory (NVRAM), magnetoresistiverandom-access memory (MRAM), resistive random-access memory (RRAM),Silicon-Oxide-Nitride-Oxide-Silicon memory (SONOS), floating junctiongate random access memory (FJG RAM), Millipede memory, racetrack memory,and/or the like.

In one embodiment, a volatile computer-readable storage medium mayinclude random access memory (RAM), dynamic random access memory (DRAM),static random access memory (SRAM), fast page mode dynamic random accessmemory (FPM DRAM), extended data-out dynamic random access memory (EDODRAM), synchronous dynamic random access memory (SDRAM), double datarate synchronous dynamic random access memory (DDR SDRAM), double datarate type two synchronous dynamic random access memory (DDR2 SDRAM),double data rate type three synchronous dynamic random access memory(DDR3 SDRAM), Rambus dynamic random access memory (RDRAM), TwinTransistor RAM (TTRAM), Thyristor RAM (T-RAM), Zero-capacitor (Z-RAM),Rambus in-line memory module (RIMM), dual in-line memory module (DIMM),single in-line memory module (SIMM), video random access memory VRAM,cache memory (including various levels), flash memory, register memory,and/or the like. It will be appreciated that where embodiments aredescribed to use a computer-readable storage medium, other types ofcomputer-readable storage media may be substituted for or used inaddition to the computer-readable storage media described above.

As should be appreciated, various embodiments of the present inventionmay also be implemented as methods, apparatus, systems, computingdevices, computing entities, and/or the like, as have been describedelsewhere herein. As such, embodiments of the present invention may takethe form of an apparatus, system, computing device, computing entity,and/or the like executing instructions stored on a computer-readablestorage medium to perform certain steps or operations. However,embodiments of the present invention may also take the form of anentirely hardware embodiment performing certain steps or operations.

Various embodiments are described below with reference to block diagramsand flowchart illustrations of apparatuses, methods, systems, andcomputer program products. It should be understood that each block ofany of the block diagrams and flowchart illustrations, respectively, maybe implemented in part by computer program instructions, e.g., aslogical steps or operations executing on a processor in a computingsystem. These computer program instructions may be loaded onto acomputer, such as a special purpose computer or other programmable dataprocessing apparatus to produce a specifically-configured machine, suchthat the instructions which execute on the computer or otherprogrammable data processing apparatus implement the functions specifiedin the flowchart block or blocks.

These computer program instructions may also be stored in acomputer-readable memory that can direct a computer or otherprogrammable data processing apparatus to function in a particularmanner, such that the instructions stored in the computer-readablememory produce an article of manufacture including computer-readableinstructions for implementing the functionality specified in theflowchart block or blocks. The computer program instructions may also beloaded onto a computer or other programmable data processing apparatusto cause a series of operational steps to be performed on the computeror other programmable apparatus to produce a computer-implementedprocess such that the instructions that execute on the computer or otherprogrammable apparatus provide operations for implementing the functionsspecified in the flowchart block or blocks.

Accordingly, blocks of the block diagrams and flowchart illustrationssupport various combinations for performing the specified functions,combinations of operations for performing the specified functions andprogram instructions for performing the specified functions. It shouldalso be understood that each block of the block diagrams and flowchartillustrations, and combinations of blocks in the block diagrams andflowchart illustrations, could be implemented by special purposehardware-based computer systems that perform the specified functions oroperations, or combinations of special purpose hardware and computerinstructions.

FIG. 3 is a block diagram of an exemplary system 1020 that can be usedin conjunction with various embodiments of the present invention. In atleast the illustrated embodiment, the system 1020 may include one ormore central computing devices 1110, one or more distributed computingdevices 1120, and one or more distributed handheld or mobile devices1300, all configured in communication with a central server 1200 (orcontrol unit) via one or more networks 1130. While FIG. 3 illustratesthe various system entities as separate, standalone entities, thevarious embodiments are not limited to this particular architecture.

According to various embodiments of the present invention, the one ormore networks 1130 may be capable of supporting communication inaccordance with any one or more of a number of second-generation (2G),2.5G, third-generation (3G), and/or fourth-generation (4G) mobilecommunication protocols, or the like. More particularly, the one or morenetworks 1130 may be capable of supporting communication in accordancewith 2G wireless communication protocols IS-136 (TDMA), GSM, and IS-95(CDMA). Also, for example, the one or more networks 1130 may be capableof supporting communication in accordance with 2.5G wirelesscommunication protocols GPRS, Enhanced Data GSM Environment (EDGE), orthe like. In addition, for example, the one or more networks 1130 may becapable of supporting communication in accordance with 3G wirelesscommunication protocols such as Universal Mobile Telephone System (UMTS)network employing Wideband Code Division Multiple Access (WCDMA) radioaccess technology. Some narrow-band AMPS (NAMPS), as well as TACS,network(s) may also benefit from embodiments of the present invention,as should dual or higher mode mobile stations (e.g., digital/analog orTDMA/CDMA/analog phones). As yet another example, each of the componentsof the system 5 may be configured to communicate with one another inaccordance with techniques such as, for example, radio frequency (RF),Bluetooth™, infrared (IrDA), or any of a number of different wired orwireless networking techniques, including a wired or wireless PersonalArea Network (“PAN”), Local Area Network (“LAN”), Metropolitan AreaNetwork (“MAN”), Wide Area Network (“WAN”), or the like.

Although the device(s) 1110-1300 are illustrated in FIG. 3 ascommunicating with one another over the same network 1130, these devicesmay likewise communicate over multiple, separate networks.

According to one embodiment, in addition to receiving data from theserver 1200, the distributed devices 1110, 1120, and/or 1300 may befurther configured to collect and transmit data on their own. In variousembodiments, the devices 1110, 1120, and/or 1300 may be capable ofreceiving data via one or more input units or devices, such as a keypad,touchpad, barcode scanner, radio frequency identification (RFID) reader,interface card (e.g., modem, etc.) or receiver. The devices 1110, 1120,and/or 1300 may further be capable of storing data to one or morevolatile or non-volatile memory modules, and outputting the data via oneor more output units or devices, for example, by displaying data to theuser operating the device, or by transmitting data, for example over theone or more networks 1130.

In various embodiments, the server 1200 includes various systems forperforming one or more functions in accordance with various embodimentsof the present invention, including those more particularly shown anddescribed herein. It should be understood, however, that the server 1200might include a variety of alternative devices for performing one ormore like functions, without departing from the spirit and scope of thepresent invention. For example, at least a portion of the server 1200,in certain embodiments, may be located on the distributed device(s)1110, 1120, and/or the handheld or mobile device(s) 1300, as may bedesirable for particular applications. As will be described in furtherdetail below, in at least one embodiment, the handheld or mobiledevice(s) 1300 may contain one or more mobile applications 1330 whichmay be configured so as to provide a user interface for communicationwith the server 1200, all as will be likewise described in furtherdetail below.

FIG. 4A is a schematic diagram of the server 1200 according to variousembodiments. The server 1200 includes a processor 1230 that communicateswith other elements within the server via a system interface or bus1235. Also included in the server 1200 is a display/input device 1250for receiving and displaying data. This display/input device 1250 maybe, for example, a keyboard or pointing device that is used incombination with a monitor. The server 1200 further includes memory1220, which preferably includes both read only memory (ROM) 1226 andrandom access memory (RAM) 1222. The server's ROM 1226 is used to storea basic input/output system 1224 (BIOS), containing the basic routinesthat help to transfer information between elements within the server1200. Various ROM and RAM configurations have been previously describedherein.

In addition, the server 1200 includes at least one storage device orprogram storage 210, such as a hard disk drive, a floppy disk drive, aCD Rom drive, or optical disk drive, for storing information on variouscomputer-readable media, such as a hard disk, a removable magnetic disk,or a CD-ROM disk. As will be appreciated by one of ordinary skill in theart, each of these storage devices 1210 are connected to the system bus1235 by an appropriate interface. The storage devices 1210 and theirassociated computer-readable media provide nonvolatile storage for apersonal computer. As will be appreciated by one of ordinary skill inthe art, the computer-readable media described above could be replacedby any other type of computer-readable media known in the art. Suchmedia include, for example, magnetic cassettes, flash memory cards,digital video disks, and Bernoulli cartridges.

Although not shown, according to an embodiment, the storage device 1210and/or memory of the server 1200 may further provide the functions of adata storage device, which may store historical and/or current deliverydata and delivery conditions that may be accessed by the server 1200. Inthis regard, the storage device 1210 may comprise one or more databases.The term “database” refers to a structured collection of records or datathat is stored in a computer system, such as via a relational database,hierarchical database, or network database and as such, should not beconstrued in a limiting fashion.

A number of program modules (e.g., exemplary modules 1400-1700)comprising, for example, one or more computer-readable program codeportions executable by the processor 1230, may be stored by the variousstorage devices 1210 and within RAM 1222. Such program modules may alsoinclude an operating system 1280. In these and other embodiments, thevarious modules 1400, 1500, 1600, 1700 control certain aspects of theoperation of the server 1200 with the assistance of the processor 1230and operating system 1280. In still other embodiments, it should beunderstood that one or more additional and/or alternative modules mayalso be provided, without departing from the scope and nature of thepresent invention.

In various embodiments, the program modules 1400, 1500, 1600, 1700 areexecuted by the server 1200 and are configured to generate one or moregraphical user interfaces, reports, instructions, and/ornotifications/alerts, all accessible and/or transmittable to varioususers of the system 1020. In certain embodiments, the user interfaces,reports, instructions, and/or notifications/alerts may be accessible viaone or more networks 1130, which may include the Internet or otherfeasible communications network, as previously discussed.

In various embodiments, it should also be understood that one or more ofthe modules 1400, 1500, 1600, 1700 may be alternatively and/oradditionally (e.g., in duplicate) stored locally on one or more of thedevices 1110, 1120, and/or 1300 and may be executed by one or moreprocessors of the same. According to various embodiments, the modules1400, 1500, 1600, 1700 may send data to, receive data from, and utilizedata contained in one or more databases, which may be comprised of oneor more separate, linked and/or networked databases.

Also located within the server 1200 is a network interface 1260 forinterfacing and communicating with other elements of the one or morenetworks 1130. It will be appreciated by one of ordinary skill in theart that one or more of the server 1200 components may be locatedgeographically remotely from other server components. Furthermore, oneor more of the server 1200 components may be combined, and/or additionalcomponents performing functions described herein may also be included inthe server.

While the foregoing describes a single processor 1230, as one ofordinary skill in the art will recognize, the server 1200 may comprisemultiple processors operating in conjunction with one another to performthe functionality described herein. In addition to the memory 1220, theprocessor 1230 can also be connected to at least one interface or othermeans for displaying, transmitting and/or receiving data, content or thelike. In this regard, the interface(s) can include at least onecommunication interface or other means for transmitting and/or receivingdata, content or the like, as well as at least one user interface thatcan include a display and/or a user input interface, as will bedescribed in further detail below. The user input interface, in turn,can comprise any of a number of devices allowing the entity to receivedata from a user, such as a keypad, a touch display, a joystick or otherinput device.

Still further, while reference is made to the “server” 1200, as one ofordinary skill in the art will recognize, embodiments of the presentinvention are not limited to traditionally defined server architectures.Still further, the system of embodiments of the present invention is notlimited to a single server, or similar network entity or mainframecomputer system. Other similar architectures including one or morenetwork entities operating in conjunction with one another to providethe functionality described herein may likewise be used withoutdeparting from the spirit and scope of embodiments of the presentinvention. For example, a mesh network of two or more personal computers(PCs), similar electronic devices, or handheld portable devices,collaborating with one another to provide the functionality describedherein in association with the server 1200 may likewise be used withoutdeparting from the spirit and scope of embodiments of the presentinvention.

According to various embodiments, many individual steps of a process mayor may not be carried out utilizing the computer systems and/or serversdescribed herein, and the degree of computer implementation may vary, asmay be desirable and/or beneficial for one or more particularapplications.

FIG. 4B provides an illustrative schematic representative of a mobiledevice 1300 that can be used in conjunction with various embodiments ofthe present invention. Mobile devices 1300 can be operated by variousparties. As shown in FIG. 4B, a mobile device 1300 may include anantenna 1312, a transmitter 1304 (e.g., radio), a receiver 1306 (e.g.,radio), and a processing element 1308 that provides signals to andreceives signals from the transmitter 1304 and receiver 1306,respectively.

The signals provided to and received from the transmitter 1304 and thereceiver 1306, respectively, may include signaling data in accordancewith an air interface standard of applicable wireless systems tocommunicate with various entities, such as the server 1200, thedistributed devices 1110, 1120, and/or the like. In this regard, themobile device 1300 may be capable of operating with one or more airinterface standards, communication protocols, modulation types, andaccess types. More particularly, the mobile device 1300 may operate inaccordance with any of a number of wireless communication standards andprotocols. In a particular embodiment, the mobile device 1300 mayoperate in accordance with multiple wireless communication standards andprotocols, such as GPRS, UMTS, CDMA2000, 1xRTT, WCDMA, TD-SCDMA, LTE,E-UTRAN, EVDO, HSPA, HSDPA, Wi-Fi, WiMAX, UWB, IR protocols, Bluetoothprotocols, USB protocols, and/or any other wireless protocol.

Via these communication standards and protocols, the mobile device 1300may according to various embodiments communicate with various otherentities using concepts such as Unstructured Supplementary Service data(USSD), Short Message Service (SMS), Multimedia Messaging Service (MMS),Dual-Tone Multi-Frequency Signaling (DTMF), and/or Subscriber IdentityModule Dialer (SIM dialer). The mobile device 1300 can also downloadchanges, add-ons, and updates, for instance, to its firmware, software(e.g., including executable instructions, applications, programmodules), and operating system.

According to one embodiment, the mobile device 1300 may include alocation determining device and/or functionality. For example, themobile device 1300 may include a GPS module adapted to acquire, forexample, latitude, longitude, altitude, geocode, course, and/or speeddata. In one embodiment, the GPS module acquires data, sometimes knownas ephemeris data, by identifying the number of satellites in view andthe relative positions of those satellites.

The mobile device 1300 may also comprise a user interface (that caninclude a display 1316 coupled to a processing element 1308) and/or auser input interface (coupled to a processing element 308). The userinput interface can comprise any of a number of devices allowing themobile device 1300 to receive data, such as a keypad 1318 (hard orsoft), a touch display, voice or motion interfaces, or other inputdevice. In embodiments including a keypad 1318, the keypad can include(or cause display of) the conventional numeric (0-9) and related keys(#, *), and other keys used for operating the mobile device 1300 and mayinclude a full set of alphabetic keys or set of keys that may beactivated to provide a full set of alphanumeric keys. In addition toproviding input, the user input interface can be used, for example, toactivate or deactivate certain functions, such as screen savers and/orsleep modes.

The mobile device 1300 can also include volatile storage or memory 1322and/or non-volatile storage or memory 1324, which can be embedded and/ormay be removable. For example, the non-volatile memory may be ROM, PROM,EPROM, EEPROM, flash memory, MMCs, SD memory cards, Memory Sticks,CBRAM, PRAM, FeRAM, RRAM, SONOS, racetrack memory, and/or the like. Thevolatile memory may be RAM, DRAM, SRAM, FPM DRAM, EDO DRAM, SDRAM, DDRSDRAM, DDR2 SDRAM, DDR3 SDRAM, RDRAM, RIMM, DIMM, SIMM, VRAM, cachememory, register memory, and/or the like. The volatile and non-volatilestorage or memory can store databases, database instances, databasemapping systems, data, applications, programs, program modules, scripts,source code, object code, byte code, compiled code, interpreted code,machine code, executable instructions, and/or the like to implement thefunctions of the mobile device 1300.

The mobile device 1300 may also include one or more of a camera 1326 anda mobile application 1330. The camera 1326 may be configured accordingto various embodiments as an additional and/or alternative datacollection feature, whereby one or more items may be read, stored,and/or transmitted by the mobile device 1300 via the camera. The mobileapplication 1330 may further provide a feature via which various tasksmay be performed with the mobile device 1300. Various configurations maybe provided, as may be desirable for one or more users of the mobiledevice 1300 and the system 1020 as a whole.

The invention is not limited to the above-described embodiments and manymodifications are possible within the scope of the following claims.Such modifications may, for example, involve using a different source ofenergy beam than the exemplified electron beam such as a laser beam.Other materials than metallic powder may be used, such as powder ofpolymers or powder of ceramics.

That which is claimed:
 1. A computer program product comprising at leastone non-transitory computer-readable storage medium havingcomputer-readable program code portions embodied therein, thecomputer-readable program code portions comprising at least oneexecutable portion configured for: depositing, on top of a supportsurface, at least one portion of a new layer of powder material with apowder distributor, the powder distributor having a first side and asecond side opposing the first side, the first side oriented in adirection of movement of the powder distributor during the depositing;and heating, via an energy beam and without fusing, said at least oneportion of said new layer of powder material, wherein: said heatingwithout fusing occurs while simultaneously depositing said at least oneportion of said new layer of powder material; said heating withoutfusing of said at least one portion of said new layer of powder materialoccurs at least in at least one area located adjacent and external tothe second side of the powder distributor; and said energy beam forheating without fusing is the same energy beam for fusing said powdermaterial for forming said three-dimensional article.
 2. The computerprogram product according to claim 1, wherein said heating, via theenergy beam and without fusing, additionally heats a support surfaceunder said at least one portion of said new layer of powder material,wherein said support surface is a previously deposited layer of powdermaterial, the previously deposited layer of powder material having beenpreviously at least partially fused.
 3. The computer program productaccording to claim 1, wherein said heating, via the energy beam andwithout fusing, additionally heats a support surface under said at leastone portion of said new layer of powder material, wherein said supportsurface is heated to a temperature insufficient for said layer of powdermaterial, on top of said support surface, to self-sinter.
 4. Thecomputer program product according to claim 1, wherein said new layer ofpowder material is heated to maintain a predetermined temperatureinterval before fusing said layer of powder material.
 5. The computerprogram product according to claim 1, further comprising, subsequent tosaid heating, fusing, via said at least one executable portion, said newlayer of powder material with said energy beam.
 6. The computer programproduct according to claim 5, further comprising moving, via said atleast one executable portion, said energy beam, wherein said energy beamis switched off when moving said energy beam from heating said supportsurface to heating said new layer of powder material or vice versa. 7.The computer program product according to claim 1, further comprisingproviding a security distance (d) between the powder distributor and theenergy beam when heating said new layer of powder material.
 8. Thecomputer program product according to claim 1, wherein the at least oneexecutable portion is further configured for: heating, via the energybeam and without fusing, a support surface under said at least oneportion of said new layer of powder material; and providing a securitydistance (e) between the powder to be distributed and the energy beamwhen heating said support surface.
 9. The computer program productaccording to claim 1, wherein said heating of said new layer of powdermaterial while depositing said new layer of powder material isconfigured to provide said heating in at least one of: a straight-lineconfiguration, a meandering-line configuration, or a randomlydistributed scan line of predetermined length configuration.
 10. Thecomputer program product according to claim 9, wherein said heating ofsaid new layer of powder material while depositing said new layer ofpowder material is synchronized with movement of said powderdistributor.
 11. The computer program product according to claim 1,wherein said heating of said new layer of powder material whiledepositing said new layer of powder material is synchronized withmovement of said powder distributor.
 12. A computer program productcomprising at least one non-transitory computer-readable storage mediumhaving computer-readable program code portions embodied therein, thecomputer-readable program code portions comprising at least oneexecutable portion configured for: depositing, on top of a supportsurface, a new layer of powder material with a powder distributor, thepowder distributor having a first side and a second side opposing thefirst side, the first side being oriented in a direction of movement ofthe powder distributor during the depositing; simultaneously with saiddepositing step and via an energy beam, heating without fusing at leasta portion of said new layer of powder material, the portion being heatedwithout fusing being located at least adjacent and external to thesecond side of the powder distributor; and following said heatingwithout fusing step, fusing at least said portion of said new layer ofpowder material with said energy beam.
 13. The computer program productof claim 12, wherein said depositing and heating without fusing stepsare executed via at least one computer processor.
 14. The computerprogram product according to claim 12, wherein said depositing, heatingwithout fusing, and fusing steps are executed via at least one computerprocessor.
 15. The computer program product according to claim 12,wherein the at least one executable portion is further configured for:simultaneously with said depositing step and via the energy beam,heating without fusing one portion of said support surface; and movingsaid energy beam, wherein said energy beam is switched off when movingsaid energy beam from heating said support surface to heating said newlayer of powder material or vice versa.
 16. The computer program productaccording to claim 12, further configured for providing a securitydistance (d) between the powder distributor and the energy beam whenheating said new layer of powder material.
 17. The computer programproduct according to claim 12, further configured for: simultaneouslywith said depositing step and via the energy beam, heating withoutfusing one portion of said support surface; and providing a securitydistance (e) between the powder to be distributed and the energy beamwhen heating said support surface.
 18. The computer program productaccording to claim 12, wherein said heating of at least said portion ofsaid new layer of powder material while depositing said new layer ofpowder material is configured to provide said heating in at least oneof: a straight-line configuration, a meandering-line configuration, or arandomly distributed scan line of predetermined length configuration.19. The computer program product according to claim 12, wherein saidheating of at least said portion of said new layer of powder materialwhile depositing said new layer of powder material is synchronized withmovement of said powder distributor.